Folding door structure



June 26, 1952 O B. W. MERRILL ETAL 3,040,806

FOLDING DOOR STRUCTURE Filed Dec. 31, 1958 2 Sheets-Sheet l June 26, 1962 B. w. MERRILL ETAL V 3,040,806

FOLDING DOOR STRUCTURE Filed Dec. 3l, 1958 2 Sheets-Sheet 2 INVENTORS. B6/2726i WMe/HLM dew-672i 0 Hdd@ Ham@ PZLmme/mafz LMMV% Unitcd States Patent() 3,040,806 FLDNG DGR STRUCTU Bennett W. Merrill, Clesent t). Fields, and Hollis P.

Zimme, New Castle, 1nd., assignors to New Castle Products, inc., New Castle, lud., a corporation of Indiana Filed Dec. 31, 1953, Ser. No. 784,139

Claims. (El. 16th- 199) The present invention is directed to a new and improved folding door structure formed from a plurality of hingedly interconnected rigid panels, the panel structure, hinge connections and hardware used in the fabrication and operative mounting of the structure being designed, selected and arranged for improved door fabrication with features providing for efficiency in door structure operation and maintenance.

It is an object of the present invention to provide a new and improved foldable door structure making use of hingedly interconnected rigid panel sections.

Another object is to provide a new and improved folding door structure formed from at least substantially rigid, plank-like panel members hingedly interconnected along adjacent vertical edge margins for relative movement into folded or contracted condition, the hinge connections incorporating therein new and improved structural features providing `for controlled relative movement between the individual panel members.

Other objects not speciiically set forth will become apparent from the following detailed description made in conjunction with the drawings wherein:

FIG. l is a fragmentary, partly sectioned elevation of the lfolding door structure of the present invention illustrating the same operatively mounted in its unfolded or fully extended condition in a doorway; n

FlG. 2 is a fragmentary, partly sectioned top plan view of the door structureof FIG. 1 taken :generally along line 2-2 in FIG. l;

FlG. 3 is a fragmentary top plan view of the door structure illustrating the same in its fully contracted or folded condition;

FIG. 4 is an enlarged sectional view taken generally along line 4-4 of FIG. l and illustrating the structural features and operative functioning of the lead post or panel of the door structure as well as its modified hinge connection with a panel immediately adjacent thereto;

FIG. 5 is an enlarged fragmentary section of a preferred suspension used in mounting the lead post of the door structure, this View being taken generally along line 5-5 of FIG. l;

FIG. 6 is an enlarged section of the new and improved hinge connection of the door structure taken generally along line 6-6 of FlG. l;

PEG. 7 is a view similar to FlG. 6 illustrating operative functioning of the hinge connection when the .door structure is in its contracted or fully folded condition; and

FiG. 8 is an enlarged fragmentary perspective of a flexible hinge strip forming -a part of the new and improved hinge connection of the present invention.

FIGS. l and 2 illustrate the folding door structure 10 of the present invention mounted in its operative posi-v tion within a doorway defined by a ceiling area 11 and opposite side jambs 12 and 13. The door structure 10 is formed from a plurality of rigid, or at least relatively rigid panel members which include a series of full panels 14 and four half panels 15, 16, 17 and 18. Adjacent panels 14-18 are hingedl-y interconnected by hinge connections forming a part of the present `invention and each being generally designated by the numeral 19. The half panel 15 constitutes a jamb post and is lixedly attached to the door jamb 12 by a plurality of screws 20 l ICC (see FIG. l'1). The half panel 16 interconnects the jamb post panel 15 with the nearest full panel 14. The half panel 17 interconnects the half panel lead post 18 with the nearest full panel 14 and the lead post 18 is movable into sealing abutment with a vertically extending jamb moulding strip 21 carried by the door jamb 13.

ln addition to the special hinge connections 19, adjacent panels are hingedly interconnected by hinge plates 22 suitably fastened by screws 23 rto the top surfaces of each of the panels. Adjacent interconnected Vends of the hinge plates 22 are provided with overlapped Aand cooperatively offset connecting ear portions 24 which are suitably pivotally interconnected through aligned apertures therein by rivet-type pins 25. The ceiling 11 of the door structure has attached thereto Ian overhead trolley track 26 which is particularly shown in FIG. 5 in cross section as being of generally inverted U-shape. The track 26 includes a top attaching wall 27, through which a series of spaced screws 2S are received to attach the track to the ceiling 11, and spaced downwardly directed side walls 29. The bottom margins of the side walls 29 are rolled inwardly to define 4a pair of spaced tracks 30 providing concave inner or upper surfaces in which the wheel members of a standard form of trolley 31 are received. A

strip of cushioning material 32, such as felt, is interposed between the track Z7 and the ceiling 11.

-ln FIG. l it will be noted that the lefthandportion of the door structure 10 is supported by the fixed attachmeut of the jamb post 15 to the door jamb 12. Alternatively positioned, intermediate full panels 14 are supported overhead by trolleys 31 carried iu the track 26, each trolley having attached thereto a hanger 33 which extends downwardly between the Wheel member tracks 30 and through the `adjacent hinge plates 22 with which they are attached on the inner sides thereo` for pivoting about their longitudinal axes. The pivotal attachment of the hangers 33 to adjacent hinge plates 22 permits movement of the panels 14 associated therewith relative to the track 26 during folding and unfolding of the door structure 1?. Complete folding thereof into the fully stacked condition is illustrated in FIG. 3.

Referring to FIGS. 1, 2 and 5, a pair of trolleys 31 are cooperatively attached to the lead post 1S through a trolley hanger 34 which is in the form of an inverted handle having its ends attached to the spaced trolleys 32 and having its main horizontal portion received through a sleeve portion 35 forming a part of a hangerplate or bracket 36 which is received downwardly over the top portion of the lead post 18 and is fixed thereto by transverserivets 37. The hanger 34 maintains the lead post 1S in parallel relation to the longitudinal axis of the track 26 thus preventing the same from any folding movement such as occurs in connection with the remaining intercon-V nected panels. This yarrangement provides for aligned abutment of a sealing gasket 38 mounted along the vertical leading edge 3'91 of the lead post 1S with the jamb moulding strip 21. The `details of these structural features are shown in FIG. 4 and it will be noted that the sealing strip 38, which may be of any suitable configuration formed from rubber or rubber-like material, includes an integral attaching rib portion 4i) which is received within a continuous countersunk grooved area 41 formed in the leading edge .39 of the lead post 18. The jamb moulding strip 21 is suitably secured to the door jamb 13 :by` screwsV 42 andthe outer surface thereof is V-shaped to receive the nose portion of the gasket 38.

To aid in holding the door structure 10 in its closed position with the sealing gasket 38 received in sealing engagement within the V-shaped groove of the jamb moulding strip 21, a spring plate 43 is mounted in the track 26 for engagement with one of the trolleys 31 as shown in FIG. l. One end of the spring plate 43 is attached by one of the track screws 28 against the inner surface of the top wall 27 of the track and the remaining end is retained in inwardly projecting, tensioned relation by v For grasping'the door Vstructure i6 during opening and closing of the same, door pulls 4d lare carried on both sides of the lead post 18. Obviously, door latching and locking hardware may also be carried by the lead post 18 but such hardware is not illustrated as it-does not form a part of the present invention. As shown in FIG. 5, wood trim strips 45'may lbe suitably attached to the ceiling 11 by screws i6 for decorative enclosing of the track 26. In this respect, Vany suitable material may be used as trim.

The new and improved structural features of the hinge connections 19 are illustrated in detail in FIGS. 68. Referring lirst toFIG. 8, a flexible hinge strip 46 formed from plastic, rubber, or rubber-like material constitutes an important element of each hinge connection 19. The strip 46Vincludes a central exible web portion 4'7 having integrally formed along opposite side margins thereof,

enlarged rib-like marginal formations 4S. lt will be noted that the ribs 48 are outwardly directed along one face of the strip 46 and are-each relatively thick. For mounting each strip 46.relative toadjacent door structureV panels, the vertical edge face of each panel is provided with relatively'narrow, outwardly opening groove 49 which extends throughout the entire length or Vheight' of each panel. Between each groove 49 and opposite faces of a panel are ungrooved edge portions Sti and 51.` 'The ungrcoved edge portion 51 is inwardly offset relative to the edge portion 50 preferably to an extent of the thickness ofthe flexible web portion 47 of the hinge strip 46. The groove i9 is more closely adjacent one 'face' of the panel carrying the same than thevother face for proper utilization of the strip 46 as will be apparent. i f

FIGS. 6 and 7 particularly illustrate the manner of mounting each hinge `strip 46 in adjacent grooves 49 of adjacent panels and it `will be noted that the ribs 48 are received within 4the oppositely positioned grooves with the flexible webportion-Ll being received in the offset edge portions 51.V VTo hold the ribs 4S in the oppositely positioned grooves 49 of adjacent panels, a moulding strip 520i generally tapering cross section is mounted along the vertical-edge of each panel in groove overlapping relation. Each moulding strip 52 is provided with an angled abutment face terminating in a shoulder S31-which projects outwardly from ythe vertical edge of its supporting panel toward the shoulder 53 of the moulding strip 52 carried by theadjacent panel. The taper ofweach moulding strip 52 is directed inwardly toward the center of the flexible web portion 47 of the hinge strip 46.'. YThe tapered end portion of each moulding strip 512 substantially overextends its adjacent; groove 49 and virtually covers the ofiset edge portion 51 while holding the outer area of the flexible web portion ofthe hinge strip 46 therebetween. The moulding strips 52 may be mounted in any suitable manner to the vertical edges of the panels such as by gluing, nailing', etc; Preferably, as shown in FIG. 4, each moulding strip 52-will have a brad 54 driven therethrough adjacent the tapered nose portion thereof while additionally adjacent the tapered4 nose portion thereof-while additionallyrextending through the exible web portion 47 of the hinge strip and the oifset edge portion S1 of the panel.,` The brads 54 can, by way of example, be carried near the bottom and top of each moulding strip 52 for the purpose of strengthening the hinge connection 19'Y and preventing inadvertent sliding of the hinge strip 46 relativeto thehpanel. l l l FIG. 6 illustratesY adjacent panels 14 in their extended condition illustrating operative functioning of the moulding strips 52 in controlling the extent to which the adjacent panels 14- are moved toward coplanar relation. The

outer tapered surfaces of adjacent moulding strips 52 are brought into engagement with one anotherto limit the extent of movement of adjacent panels 14 toward coplanar relation. In this respect, adjacent interconnected panels are limited in their degree of movement toward-mutual coplauar relation to the extent illustrated in FIG. 2 wherein the door structure i94 is shown in its fully extended condition. The hinge connections 19 are alternately oppositely directed and reversed inpositionrat opposite edges of each of the panels to cause the panels to fold back and forth against each other in their contracted positions. HG. V7 illustrates the fully contracted position of the two interconnected panels 14 and it will be noted Vthat cornplete folding of adjacent panels into surface-to-surface parallel relation is obtained. In the completelyfolded or unfolded positions of vthe panels, the hinge strips 46 function to completely close 01T the hinge areas between adjacent panels. This provides a continuousclosure and is of significance in connection with the soundproofng efficiency of the door structure. The flexible web portion 47 of each hinge strip 46 completely spans the joint between adjacent panelsrand upon unfolding of the panels into moulding strip abutment as shown in FIG. 6, the web portion 47 becomes substantially taut. It will further be noted that the tapered configuration of the cooperating moulding strips 52 prevent reverse folding of the door structure and maintain the adjacent interconnected panels in broken relation so as to provide for immediate and controlled folding movement of the door structure.

In connection with maintaining the lead post 18 parallel to the track 26 as previously described, it willbe noted that the hinge connection 19 interconnecting the lead post 1S with the adjacent half panel 17 includes moulding strips 52 whose engaging faces are further angled to permit parallelpositioning ofthe lead post 18. In all other respects the hinge connection 19 betweenv the lead post 18 and half panel 17 functions in the same manner as previously described... A The door panels may be formed from any suitable material which supplies the requisite rigidity for eicient operation of the door structure in the manner described. As illustrated, each panel is formed from a central planklike wood core 5S the outer surfaces of which are provided with a finishing veneer 56 for decorative purposes. Folding door structures fabricated in the manner described are capable of long-life operationin an ei`ncient manner and maybe readily and efficiently fabricated. Y

Obviously, certain modications and variations of the invention as hereinbefore set forth may be made without departing from the spirit and scope thereof, and there- `forelonly suchn limitations should ybe imposed Vas are indicated in the appended claims.

We claim:

l. In a door of the type characterized by a plurality of vertically elongated panelsvvhich are suspended from an overhead track and are serially connected along their vertical .edges for Vfolding and unfoldingmovement between' contracted and extended positions in a doorway, the vertical edges of said panels being provided with outwardly-opening grooves, a plurality of ilexible hinge strips provided with enlarged marginal formations, ,which formations of each strip are positioned within the grooves in theedges of adjoining panels with the intervening web portion of each hinge strip positioned outwardly of the grooves against the portions of the edges of said panels ,between theY grocves'and the faces of the panels, and a plurality of moulding-strips secured to and along ung'rooved portions of the edges of saidpanels in uninserted laterally overlapping relation to the grooves and to the marginal Y,formations of the iexible hinge strips within the Ygrooves to close oft` said grooves to an extent that said marginal formations are trapped therein and the web portions are held for controlled iiexing, the outer edges of said moulding strips being angularly disposed with respect to the -faces of the panels for abutment with each other in the lfully extended positions of the panels, in which fully extended positions the web portions of the flexible hinge strips span the joints between the panels, and the flexible hinge strips and moulding strips being reversed in position at opposite edges of each of the panels to cause the panels to fold `back and forth against each other in their contracted positions, said moulding strips and hinge strips fully covering the edges of said panels with said moulding strips cooperating with said hinge strips to provide controlled positioning of the intervening web portions of said strips against the edges of said panels -between the grooves and the faces of the panels in both the face-to-face stacked positions and zigzag fully extended positions of said panels.

2. In a door of the type characterized by a plurality of vertically elongated panels which are suspended from an overhead track and are serially connected along their vertical edges for folding and unfolding movement between contracted and extended positions in a doorway, the Vertical edges of said panels being provided with outwardly opening grooves, a plurality of exible hinge strips provided with enlarged marginal formations, which formations of each strip are positioned within the grooves in the edges of adjoining panels with the intervening web portion of each hinge strip positioned outwardly of the grooves against the portions of the edges of said panels between the grooves and the faces of the panels, the portions of the edges against which the web portion of each hinge strip is positioned being inwardly offset with respect to ungrooved portions on the opposite sides of the grooves, and a plurality of moulding strips secured to and along ungrooved portions of the edges of said panels in uninserted laterally overlapping relation to the grooves and to the marginal formations of the exible hinge strips within the grooves to close off said grooves to an extent that said marginal lformations are trapped therein and the web portions are held for controlled flexing, the outer edges of said moulding strips being angularly disposed with respect to the faces of the panels for abutment with each other in the fully extended positions of the panels, in which fully extended positions the web portions of the flexible hinge strips span the joints between the panels, and the flexible hinge strips and moulding strips being reversed in position at opposite edges of each of the panels to cause the panels to fold back and forth against each other in their contracted positions.

3. In a door of the type characterized yby a plurality of vertically elongated panels which are suspended from an overhead track and are serially connected along their vertical edges for folding and unfolding movement between contracted and extended positions in a doorway, the vertical edges of said panels 'being provided with outwardly opening grooves, a plurality of flexible hinge strips provided with enlarged marginal formations, which formations of each strip are positioned within the grooves in the edges of adjoining panels with the intervening web portion of each hinge strip positioned outwardly of the grooves against the portions of the edges of said panels between the grooves and the faces of the panels, and a plurality of moulding strips of generally tapering cross section secured atly to and along the ungrooved porfully extended positions of the panels, in which fully exf tended positions the web portions of the flexible hinge strips span the joints between the panels and are substantially taut, said hinge strips'in relaxed condition being of generally channel-like shape for ready positioning ofv the enlarged marginal formations thereof in grooves of adjacent panels arranged in face-to-face relation during assembly of said door fand prior to moulding strip attachment thereto, and the ilexible hinge strips and moulding strips being reversed in position at opposite edges of each of the panels to cause the panels to fold back and forth against each other in their contracted positions.

4. In a door of the type characterized by a plurality of vertically elongated panels which are suspended from an overhead track and are serially connected along their vertical edges for folding and unfolding movement between contracted and extended positions in -a doorway, the vertical edges of said panels being provided with outwardly opening grooves, .a plurality of tdexible hinge strips provided with enlarged marginal formations, which formations of each strip are positioned within the grooves in the edges of adjoining panels with the'intervening web portion of each hinge 'strip positioned outwardly of the grooves against the portions of the edges of said panels between the grooves and the faces of the panels, the portions of the edges against which the web portion of each hinge strip is positioned being inwardly offset with respect to ungrooved portions on the opposite sides of the grooves, and a plurality of moulding strips secured to and along ungrooved portions of the edges of said panels in uninserted laterally overlapping relation to the grooves and to the marginal formations of the ilexible hinge strips within the grooves to close off said grooves to an extent that said marginal formations are trapped therein and the web portions are held for controlled exing, said hinge strips in relaxed condition being of generally channel-like shape for ready positioning of the enlargedmarginal formations thereof in grooves of adjacent panels arranged in face-to-face relation during assembly of said `door and prior to moulding strip attachment thereto, `and the flexible hinge strips and moulding strips being reversed in position at opposite edges of each of the panels to cause the panels to fold back and forth against each other in their contracted positions.

5. The door of claim 4 wherein the portions of the edges against which the web portion of each hinge strip is positioned are inwardly offset to a depth approximat-` ing the thickness of the web portion.

References Cited in the file of this patent UNITED STATES PATENTS 2,210,652 Dennett Aug. 6, 1940 2,507,965 Eichner May 16, 1950 2,812,023 Laity et al. Nov. 5, 1957 

